SOUTHWEST RESEARCH INSTITUTE

Engine Design Past Project

Design of Turbocharging System for a Mining Truck Engine

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SwRI Project:	03-1074
Client:	Confidential
Duration:	12 Months

A project to redesign the turbocharging system of a large mining truck engine was initiated between Southwest Research Institute (SwRI) and a large US engine and equipment manufacturer. The redesign was intended to solve problems of turbocharger rotor failure and air handling system seal failure due to the high temperatures of the compressor outlet air. SwRI work scope included incorporating the new turbocharging equipment, redesigning all the air ducting including several major castings, and redesigning all of the auxiliary equipment including oil lines, coolant lines, access steps, and various brackets and miscellaneous parts.

Design and Reduction in Parts Count

Three-dimensional design work was done using Pro/ENGINEER as a solid modeler. Several concepts were developed and analyzed for their improvement of the design and reduction in parts count. A significant reduction in parts count and combination of functions within single castings realized increased reliability. Incorporating steel bellows to accommodate relative motion caused by thermal growth solved the seal problem.

Prototyping Process for Turbocharging System

SwRI participated in the prototyping process by interfacing with casting and machining vendors, fabricating some of the prototype hardware, traveling to the client's facilities to assist in buildup and assembly checks, resolving field problems, and finally preparing all of the manufacturing drawings for the new components and assemblies.

The new turbocharging system is now in production and has successfully addressed the problems.

For more information about this engine design project, or how you can contract with SwRI, please contact Mark Tussing at mtussing@swri.org or (210) 522-2628.

enginedesign.swri.org

Contact Information

Mark Tussing

Engine Design

(210) 522-2628

mtussing@swri.org

enginedesign.swri.org

Related Terminology

engine design

engine analysis

thermodynamic analysis

mechanical design

mechanical analysis

engine emissions

fuel economy

engine power

unique engines

engine components

turbocharger rotor failure

air handling system seal failure

reduction in parts count

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Southwest Research Institute^®(SwRI^®), headquartered in San Antonio, Texas, is a multidisciplinary, independent, nonprofit, applied engineering and physical sciences research and development organization with 11 technical divisions.

December 28, 2012